Electrical connection and art of making the same.



'w. u. HODGSON.

ELECTRICAL CONNECTION AND ART OF MAKING THE SAME.

APPLICATION FILED MAY 16, 1911.

1,275,687. Patented Aug. 13, 1918.

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WILFRED ID. HODGSON, 0F AKRON, OHIO.

ELECTRICAL CONN ECTION AND ART OF MAKING THE SAME.

Specification of Letters Patent.

Patented Aug. 13, 1918.

Application filed May 16, 1917. Serial No. 168,927.

To all whom it may concern:

Be it known that I, WILFRED D. .HoDcsoN, a citizen of the United States, and a resident of Akron, in the county of Summit and State of Ohio, have invented an Improvement' in Electrical Connections and Art of Making the Same, of which the following is a specification.

This invention relates to the connection of spaced members and an art of making said connection. With regard to the more specific features thereof, this invention relates to the interconnecting 0f the conducting members of electric machinery.

One of the objects of' this invention is to provide in electrical apparatus chea and compact yet durable, reliable and e cient metallic conducting circuits.

Another object is to provide practical and secure means for interconnecting the con ductors forming the elements of windings of electrical apparatus and to interconnect such elements so as to form a resultant homogeneous and continuous structure of maximum electrical and -mech'anical eflicien'cy.

Another object is to provide a method of constructing electrical circuits of the above type that can be inexpensively and simply carried on,

Other objects will be in part obvious or in part hereinafter pointed out.

The invention accordingly consists in the features of construction, combinations ofelesteps, all as hereinafter pointed out and the ments, arrangements of parts and in the several steps and relation and order of such scope of the application, of which, will be indicated in the following claims.

The accompanying drawings, in which are shown one or more. of the various possible embodiments of the several mechanical features of this invention,

Figures 1, 2 and 3 show several modified forms which may be given the members to be interconnected and which form a part of the rotor electrical circuit.

Fig. 4 is a partial elevation, and

Fig.- 5 is a sectional view taken along the circumferential line 55 of Fig. 4.

Fig. 6 is a partial elevation like Fig. 4, but on a small scale, showing the rotor'a'nd the spaced conducting members in assembled relation, and

' operate.

of the inability thereof to effectively withstand the conditions of excessive vibration and heat under which such motor elements The above and other defects are avoided, and many advantages obtained, by the features of this invention.

ratus employed in carrying out this inven The process whereby some of the objects of this invention are attained may be carried on substantially as follows:

There is first formed an induction motor rotor, built up of sheet iron punchings or laminations, mounted upon a shaft. In the .sl'ots formed in the periphery of the rotor are then placed the bars forming the conducting elements of the rotor electric circuit, and are suitably insulated from the rotor proper. The extremities of the bars protruding beyond the end faces of the rotor are then preferably slit pa-rallelto the axes of the bars and along the, diameter of the bar cross section. The two lugs 1314 so formed on each bar 11, as shown in Fig. 1,

are then bent over'at' substantially right angles to the axis of the bar 11 itself, and so as to lie in substantially the same plane, and to extend in the direction ofthe circumference 5--5, thus giving the bar substantiall a T form. The length of th'e ap-pending ugs 13--14 may depend upon the spacing of the conducting elements 11 themselves, when placed in position inthe slots 16 of the rotor, as shown in section in Fig.

5 and'in elevation in Fig. 4.

Some of the features of this invention may likewise be achieved by bending over the ends '12 of the conducting elements 11 pr0- truding beyond the end faces of the rotor at substantially right angles to the bar itself, as shown in Fig. 2, iving the bar substantially an l. shape. 5r the bars 11, extending beyond the rotor end faces, may be interconnected at their protruding extremities by a member 15 of relatively small cross section, as shown in Fig. 3.

A partially protective covering 18 is now applied to the rotor. This covering 18 is made of a suitable non-conducting material, capable of resisting the corrosive action of acids and other chemicals, and lis preferably of a plastic composition, which may be readily formed and molded into any desired shape. The covering 18 is made to incase the end faces of the rotor 17, extending partially along the cylindrical surface of the rotor as indicated at 22 in Fig. 7 and may completely incase the rotor shaft 19, as shown in Figs. 6 and 7. The'plastic covering 18 is given such a form as to'leave exposed the T-projections 13-14 of the bars 11, which, as previously described, are placed so that the lugs 13-14 extend in the direction of the circumference 5-5. Also portions of the end face of the rotor are left exposed between adjacent conductor extremities, as at 20, forming a mold of substantially annular form extending around the end face of the rotor and including therein the conductor extremities 13-14. This annular mold is shown in elevation in Fig. 4 and in cross section in Fig. 5, which figures also show the lugs 13-14 lying within the mold formed by the 'covering'18.'

The covering 18 is furthermore given such. form that the annular mold immediately over the unprotected portions 20 of the rotor is given a greater Width than at the section adjacent the conductor extremities 13-14, the Width at this latter section bei-ngmade substantially that of the lugs 13-14 themselves. This construction of the annular mold is for a purpose to be hereinafter described. The plastic covering 18 after its application to rotor 17 and its proper formation thereon, is allowed to harden and set, after which the conducting bars 11 are ready for the next step of the process. I

After the parts exposed by the partially protective cover '18 have been thoroughly cleaned from foreign matter, and particularly from fatty substances in any suitable manner, the rotor,"with its conductor extremities 13-14 protruding into the annular mold, is now placed in a chemical bath 24 contained in a suitable receptacle 23, asshown in F 1g. 7, the depth of immersion,-

being such as to completely submerge the exposed parts. The bath consists of a solution of a convenient salt of the metal of which it is desired to form the interconnecting member for the bars 11; in this instance the bars 11 are of copper, and the bath is a solution of preferably copper sulfate .of suitable concentration. A plate 25 of reamps? negative terminal of the aforesaid source of current. A heavy current is now made to pass through the solut1on,'ente'r1ng at the copper plate anode 25, and leaving the solution at the lugs 13-14 and the unprotected portions 20 of the end face of the rotor which together constitute the cathode. The

passage of this current in the manner described, causes the H ionic deposition of a layer 26 of copper indicated in the dotted lines in Fig. 5 into the annular mold previously described. This deposition takes place upon the extremities 13-14 of the bars 11 which extend into the mold and upon the unprotected portion 20 of the rotor face and is of substantially uniform thickness throughout, as indicated by the dotted line 26. After the deposition of metal to the desired extent has taken place, the current is interrupted and the rotor removed from the bath. The protective covering 18 is then removed from the rotor, leaving the deposited interconnecting member 27 intact upon the end face of the rotor.

It will be seen that a process has been devised, whereby the spaced conducting members 11 are interconnected in such a manner that the extremities of the bars when shaped in the manner heretofore described, constitute a part of the interconnecting member 27 itself, and by the electrolytic deposition as herein described, forms therewith 'a molecularly homogeneous and continuous structure. In order that the cross section of the resultant interconnection 27 will be uniform throughout, the mold is made greater in Width at the sections 20 thereof, than at the sections adjacent the lugs 13-14, and this width is so proportioned with respect to the latter, that the cross section at 20 after the deposition is substantially equivalent to the resultant cross. section through the lugs 13-14. and the deposited metal thereon.

There is, therefore, provided a member 27,

which both mechanically, and electrically in-- terconnects the spaced bars 11, so as to form a substantially integral structure therewith,

games? more, the conducting members and their conformed extremities may be allowed to protrude beyond the end faces of the rotor and the processes carried out without departing from the spirit of this invention.

As many changes might be made in the above arrangement, and as many apparently different embodiments might be made of this invention without departing from the scope thereof, it is intended that all features hereindescribed or shown in the accompanying drawings, shall be interpreted as illustrative and not in a limiting sense.

What I claim as my invention is:

1. The art which consists in forming-an electrically interconnecting member between a plurality of electrical conductors by immersing the ends of said conductors in a bath and electrolytically depositing metal thereupon and thcrebetween.

'2. The art of forming an electrical connecting ring betwen the ends of the rotor conductors of an induction motor which consists in mounting the rotor with the ends of said conductors immersed in a bath, and

electrolytically depositing metal upon and between said conductors to form an annular interconnecting element.

3. The art which consists in forming a mechanical and electrical interconnection between a plurality of metallic conducting members by the electro-chemical deposition of a metal into a mold of predetermined form into which said members extend.

4. The art of making a metallic interconnection between metallic members which consists in electrolytically depositing said metallic interconnection upon said members and upon an auxiliary conducting member of relatively small magnitude interconnecting said members.

The art of making a metallic intercom nection between metallic members, which consists in electrolytically depositing said metallic interconnection upon said members and upon an auxiliary conducting member of relatively small magnitude interconnecting said members and to conform to a mold of predetermined form within which said conducting member is placed.v

6. The art of making a metallic interconnection between metallic members, which consists in electrolytically depositing said metallic interconnection upon said members into a mold of predetermined form, into which said members extend, whereby said interconnection is given a substantially uniform cross-section.

7. The process of interconnecting the conductors of a power-producing element of an electric motor which consists in applying a partially protective covering to said element, partially immersing said element and the extremities of said conductors in a chemical bath and electrolytically depositing an interconnecting member upon the extremities of said conductors and upon the unprotected portion of said element.

8. The process of forming an interconnecting member for the conductors on an element of electric apparatus which consists in applying a partially protective covering to said element, making the unpro tected portion of said element of predetermined form, immersing said partially protected element and the extremities of said conductors in a chemical bath and electrolytically depositing an interconnecting member upon said conductors and upon said unprotected portion of said element, where by said member is given said predetermined form.

9. The process of forming an interconnecting member for a plurality of conductors on an element of electric apparatus, which consists in applying a protective mold to and partially covering said element, making the mold such that the unprotected portion of said element is of predetermined form, and which consists further in conforming the extremities of said conductors to lie Within said mold and upon said unprotected portion of said element, immersing said partially protected element and said extremities in a chemical bath and electrolytically depositing an interconnecting member upon said conformed extremities and upon said unprotected portion of said element, whereby said member is given said predetermined form.

10. The process of forming an intercom necting member for a plurality of conductors on an element of electrical apparatus, which consists in applying to 'said element a single sheet metal lamination through; which said conductors protrude, applying a protective mold partially covering said element and said lamination, making the mold such that the unprotected portion of said lamination is of predetermined form, and which consists further in conforming the extermities of said conductors to lie within said mold and upon said unprotected portion of said lamination, immersing said partially protected parts and laniination in a chemical bath and electrolytically depositing and interconnecting member upon said conformed extremities and upon said lamination, whereby said member is given a sub stantially uniform cross-section by said predetermined form of said mold.

11. In electrical apparatus, in-combination, an. induction motor rotor having the ends of its conductors provided with projecting parts and interconnected by a ring of electrolytic metal which follows the shape of said parts and thereby interlocks therewith. a

12. In electrical apparatus, in combination an induction motor rotor, the ends of the conductors of which are provided with projecting surfaces, and an interconnecting conductor of electrolytic metal connecting said ends and resting upon said surfaces and shaped to provide a substantially uniform Cl oss-section.

13. In electrical apparatus, in combination, an induction motor rotor, the ends of the conductors of which are connected by a names? ring of electrolytic metal formed on and be- 10 tween said ends,'the portions intermediate said ends being Wider in a radial direction than the portions at the ends,

In testimony whereof I have signed my name to this specification this 12th day of 16 May, 1917.

VVILFRED D. HODGSON. 

